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Vmac Rapt Air-MF Technical Support

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SYSTEM OR PARTS AFFECTED
•
Multifunction Power Systems (MF) with ac / dc Generator, equipped with either:
o
120 V ac GFCI and 240 V ac receptacles
o
Terminal strip connections
INDEX
Receptacle-type Multifunction (ac test) ................................................................................................ 3
Terminal-strip type Multifunction (ac test) ........................................................................................... 5
Testing dc Circuits (Terminal Strip, and receptacle style generators) .............................................. 7
Bridge rectifier test ................................................................................................................................. 13
APPENDIX A ............................................................................................................................................ 15
OVERVIEW
The following tests will assist in diagnosing generator output issues.
Re-assemble the genset precisely as it was disassembled, making effort to bundle and
restrain loose wire lengths. Be mindful of wire strain and clearance from surrounding
components/bodies. Incorrectly routed harnesses present a risk of generator damage and
personal injury.
Please fill in the information below prior to sending this test sheet to VMAC Technical Support.
Customer name
Contact information - phone number
Contact information - email address
System ID number
Service Ticket number (if issued)
Engine Hours
Compressor Hours
Version
Document
Department
E
EXT-MF-005
Tech
Knowledge Base:
http://kb.vmacair.com/
Email:
tech@vmacair.com
Web:
www.vmacair.com
Technical Support
Subject
Testing Multifunction AC and DC Circuits
Revision Details
Add VSI content
Technical Support:
1(888)241-2289
Toll
Free:1(800)738-8622
Revised by
Tech
BDJ
DSB
Fax: 1(877)740-3201
Engineering
Implemented
CAB
22 Nov 2024
Page 1 of 16

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Summary of Contents for Vmac Rapt Air-MF

  • Page 1 Incorrectly routed harnesses present a risk of generator damage and personal injury.  Please fill in the information below prior to sending this test sheet to VMAC Technical Support. Customer name Contact information – phone number Contact information – email address...
  • Page 2 Technical Support Subject Testing Multifunction AC and DC Circuits TEST PROCEDURES The ac voltage test must be performed before testing the dc circuits. Without ac output from the generator, there will be no dc output. The ac tests in this instruction are divided into sections for receptacle type generators and terminal strip type generators.

  • Page 3: Receptacle-Type Multifunction (Ac Test)

    Technical Support Subject Testing Multifunction AC and DC Circuits RECEPTACLE-TYPE MULTIFUNCTION (AC TEST) 20 A circuit 20 A circuit breaker breaker (push to reset) (push to reset) 30 A circuit breaker Positive dc terminal Negative dc terminal (weld / boost) (weld / boost) Dinse 50 Dinse 50...
  • Page 4 Technical Support Subject Testing Multifunction AC and DC Circuits RECEPTACLE-TYPE MULTIFUNCTION: 240 V AC CIRCUIT TESTING  Start the Multifunction engine and allow it to warm up for 1 minute. The engine should rev up and then idle down.  Turn the generator on at the control panel.

  • Page 5: Terminal-Strip Type Multifunction (Ac Test)

    Technical Support Subject Testing Multifunction AC and DC Circuits TERMINAL-STRIP TYPE MULTIFUNCTION (AC TEST) 20 A circuit 20 A circuit breaker breaker (push to reset) (push to reset) 30 A circuit breaker Negative dc terminal Positive dc terminal (weld / boost) (weld / boost) Dinse 50 Dinse 50...
  • Page 6 Technical Support Subject Testing Multifunction AC and DC Circuits TERMINAL STRIP MULTIFUNCTION: TESTING 240V AC CIRCUITS  Start the Multifunction engine and allow it to warm up for 1 minute. The engine should rev up and then idle down.  Turn the generator on at the control panel.

  • Page 7: Testing Dc Circuits (Terminal Strip, And Receptacle Style Generators)

    Technical Support Subject Testing Multifunction AC and DC Circuits TESTING DC CIRCUITS (TERMINAL STRIP, AND RECEPTACLE STYLE GENERATORS) It is possible for a faulty dc printed circuit (pc) board to damage the welder control box! It is not possible to test the welder control box without first ensuring a good dc pc board is installed.
  • Page 8 Technical Support Subject Testing Multifunction AC and DC Circuits Figure 7  Ensure nothing is connected to the Dinse 50 dc output terminals.  Set the ARC FORCE to minimum.  Set the CURRENT knob to 100%.  Start the Multifunction engine and allow the engine to warm up for 1 minute. ...
  • Page 9 Technical Support Subject Testing Multifunction AC and DC Circuits  Ensure nothing is connected to the Dinse 50 dc output terminals.  Set the ARC FORCE to minimum.  Set the WELDING CURRENT knob to 100%.  Ensure that the WELD/charge knob is in the 0 position. ...
  • Page 10 Technical Support Subject Testing Multifunction AC and DC Circuits WELD VOLTAGES HIGH AND NON-ADJUSTABLE, OR ERROR MESSAGE “ER 0”. • Systems with first generation weld control boxes may present voltage at the dc terminals in the 60 v - 70 v range in all weld settings (Figure 7).
  • Page 11 Technical Support Subject Testing Multifunction AC and DC Circuits INSPECT CONNECTORS:  Inspect the 4 connectors that mate to the DC control board (4pin, 8pin, 14pin, 18pin), confirming that they are fully engaged with the dc pc board and that the locking tabs & levers are engaged to hold the connectors firmly in place (Figure 10).
  • Page 12 Figure 11  If the dc pc board potting surrounding the connectors is not relieved, and is preventing the locking tabs from engaging, contact VMAC Technical Support for assistance (Figure 11).  Unplug the connectors from the dc pc board.

  • Page 13: Bridge Rectifier Test

    Technical Support Subject Testing Multifunction AC and DC Circuits BRIDGE RECTIFIER TEST This test is only required if the system has failed any of the ac voltage tests.  Turn the Multifunction off and disconnect the battery.  With the generator cover off (see A500199_1901090_D.pdf for disassembly instructions), locate the bridge rectifier (Figure 13).
  • Page 14 Technical Support Subject Testing Multifunction AC and DC Circuits  With the ground lead of the multimeter connected to pin 5, connect the positive lead to the pins below and verify the voltages are within the specified range (If any pin produces a short or open circuit, the bridge rectifier has failed) (Figure 14).
  • Page 15 Improper repair presents the risk of damage to equipment, fire, and personal injury or death. VMAC does not supply pin or harness manufacturing components. Parts for the connectors below are available for purchase from select electronics distributors.
  • Page 16 Technical Support Subject Testing Multifunction AC and DC Circuits  The 18 Pin Connector cannot be serviced without re-crimping. Although the harness is removable, removal presents risk and is not recommended. 18-pin connector WIRE COLOUR WIRE COLOUR Housing: 69176-018LF EMPTY EMPTY Terminals: 47217-000LF...

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